基于图像处理的小模数齿轮测控系统的研究
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摘要
小模数齿轮目前广泛的用于高精密仪器仪表中,小模数齿轮的精度直接影响到仪器的工作性能和使用寿命,因此,小模数齿轮的检测和测量非常重要,小模数齿轮测量相比一般齿轮测量具有特殊性,其特殊性给测量带来很多困难。其特殊性表现在:1齿轮的刚度低,易变形;2齿间小,调整和对正困难;3对测量系统及量仪的自动化程度要求高;4小模数齿轮种类繁多,测量时装夹与定位困难;5受齿轮尺寸的限制,测量机械结构安排困难,目前国内外小模数齿轮测试的自动化程度低,测试仪器和设备缺少,为解决小模数齿轮测量方法落后状况,必须重视和加强小模数齿轮测量的研究和测试仪器的开发。
本文在原有的小模数齿轮测量方法的基础上,通过在三坐标测量机上加装CCD图像测头,研究利用图像处理的非接触式测量方法来测量小模数齿轮的参数,在测量过程中,首先对得到的小模数齿轮图像进行图像处理后,对渐开线齿廓边缘坐标点进行数据采样,由所得坐标点进行渐开线拟合计算得出的基圆半径值和小模数齿轮其它参数和加工误差。本文主要研究内容如下:
1.小模数齿轮测控系统总体设计,小模数齿轮测控系统分为三个部分:机械结构组成;运动控制系统:测量系统。
2.数字图像处理方法。介绍数字图像处理的方法:图像增强和图像分割。再分别介绍了一些数字图像处理的基本方法:直方图修改、灰度变换方法、图像滤波、图像锐化,边缘检测、灰度阈值法等。
3.小模数齿轮测量的数据处理。主要介绍对得到的小模数测量图像进行数字图像处理,对处理好的齿轮图像边缘进行数据采样,拟合渐开线,计算小模数齿轮其它参数和加工误差。
4.小模数齿轮测量的误差分析。主要分析在测量过程中的测量误差和产生误差的原因,计算测量误差。
Fine-pitch gear is widely used in high precision instruments and meters, and its accuracy has direct influence on the instruments' operational performance and work life span, so the detection and measurement of fine-pitch gear is vital. Meantime, due to its own particularities, there are many difficulties in the fine-pitch gear's detection including low stiffness, easy distortion; short distance between two gears, difficult to adjust; high automation requirement on measurement system; difficulties of clamping and alignment from a great variety of micron gears; difficulties of arranging mechanical structure caused by the constraint of gears' size and volume. Currently, the automation of detection and measurement of fine-pitch gear is far from satisfaction both at home and abroad, and there is the shortage of testing instrument and equipment. In order to solve the problem of behindhand situation of detection method of fine-pitch gear, enhancing the study of fine-pitch gear's detection and development of testing instrument and equipment is becoming more important.
In this paper, on the basis of the present research of fine-pitch gear's measurement, CCD image probe was mounted on the three-coordinates measuring machine to study non contact measurement method through the means of image processing with the purpose of the detection of fine-pitch gear. During the measuring procedure, we used the method of image processing to process the picture of fine-pitch gear, and then did several sets of data sampling of coordinates of involute flank profile's edge. According to the coordinates above, we finished the fit calculation about involute curve and calculated out some other parameters and mismachining tolerance with the help of base radius computed from fit results. The main contents in this paper are as follows:
1 .Measurement and control system design of fine-pitch gear, including mechanical structure composition, kinetic control system, and measurement system.
2.The study of digital image process method., including image enhancement, image segmentation and some other basic methods such as histogram modification, gray transformation, image filtration, image sharpen, edge detection, gray level threshold method, etc.
3.Data processing of fine-pitch gear's measurement. According to the coordinates above, we finished the fit calculation about involute curve and calculated out some other parameters and mismachining tolerance with the help of base radius computed from fit results
4.Error analysis of measurement of fine-pitch gear, we analyzed the measurement errors and the causes, and calculated the measurement errors finally.
本文在原有的小模数齿轮测量方法的基础上,通过在三坐标测量机上加装CCD图像测头,研究利用图像处理的非接触式测量方法来测量小模数齿轮的参数,在测量过程中,首先对得到的小模数齿轮图像进行图像处理后,对渐开线齿廓边缘坐标点进行数据采样,由所得坐标点进行渐开线拟合计算得出的基圆半径值和小模数齿轮其它参数和加工误差。本文主要研究内容如下:
1.小模数齿轮测控系统总体设计,小模数齿轮测控系统分为三个部分:机械结构组成;运动控制系统:测量系统。
2.数字图像处理方法。介绍数字图像处理的方法:图像增强和图像分割。再分别介绍了一些数字图像处理的基本方法:直方图修改、灰度变换方法、图像滤波、图像锐化,边缘检测、灰度阈值法等。
3.小模数齿轮测量的数据处理。主要介绍对得到的小模数测量图像进行数字图像处理,对处理好的齿轮图像边缘进行数据采样,拟合渐开线,计算小模数齿轮其它参数和加工误差。
4.小模数齿轮测量的误差分析。主要分析在测量过程中的测量误差和产生误差的原因,计算测量误差。
Fine-pitch gear is widely used in high precision instruments and meters, and its accuracy has direct influence on the instruments' operational performance and work life span, so the detection and measurement of fine-pitch gear is vital. Meantime, due to its own particularities, there are many difficulties in the fine-pitch gear's detection including low stiffness, easy distortion; short distance between two gears, difficult to adjust; high automation requirement on measurement system; difficulties of clamping and alignment from a great variety of micron gears; difficulties of arranging mechanical structure caused by the constraint of gears' size and volume. Currently, the automation of detection and measurement of fine-pitch gear is far from satisfaction both at home and abroad, and there is the shortage of testing instrument and equipment. In order to solve the problem of behindhand situation of detection method of fine-pitch gear, enhancing the study of fine-pitch gear's detection and development of testing instrument and equipment is becoming more important.
In this paper, on the basis of the present research of fine-pitch gear's measurement, CCD image probe was mounted on the three-coordinates measuring machine to study non contact measurement method through the means of image processing with the purpose of the detection of fine-pitch gear. During the measuring procedure, we used the method of image processing to process the picture of fine-pitch gear, and then did several sets of data sampling of coordinates of involute flank profile's edge. According to the coordinates above, we finished the fit calculation about involute curve and calculated out some other parameters and mismachining tolerance with the help of base radius computed from fit results. The main contents in this paper are as follows:
1 .Measurement and control system design of fine-pitch gear, including mechanical structure composition, kinetic control system, and measurement system.
2.The study of digital image process method., including image enhancement, image segmentation and some other basic methods such as histogram modification, gray transformation, image filtration, image sharpen, edge detection, gray level threshold method, etc.
3.Data processing of fine-pitch gear's measurement. According to the coordinates above, we finished the fit calculation about involute curve and calculated out some other parameters and mismachining tolerance with the help of base radius computed from fit results
4.Error analysis of measurement of fine-pitch gear, we analyzed the measurement errors and the causes, and calculated the measurement errors finally.
引文
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[2]徐建华.图像处理与分析.上海:科学出版社,1992.
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[8]刘欣,张元良.微型齿轮量仪及测量技术的研究.工具技术.1993.35-37
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[10]陈向伟,王龙山,图像测量技术在微型齿轮测量仲的应用.半导体光电.2004.No.6.465-469
[11]夏正良.数字图像处理.东南大学出版社.1999.1
[12]WeijingLi,Carbollo.M.High-speed micro gear inspection by evaluating Laser beam reflectiongs.Intelligent Engineering Systems Through Artificial Neural Networks.Vol.41994.987-992
[13]张国雄.三坐标测量机[M].天津:天津大学出版社,1999:1-6,138-174.
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[18]郑江,张保全,桂志国.现代齿轮技术的发展与我国齿轮制造面临的问题[J].华北工学院学报.1997,18(1):50-54.
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[20]李特文.齿轮啮合原理[M].第二版.上海:上海科学技术出版社,1984:412-425.
[21]李特文.齿轮啮合原理[M].第一版.上海:上海科学技术出版社,1964:240-322.
[22]第一汽车厂切削实验室编.圆弧齿伞齿轮加工手册[M].第一版.长春:吉林人民出版社,1959:1-10.
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[29]陈立周.机械优化设计方法[M].第三版.北京:冶金工业出版社,2005:89-105.
[30]渐开线圆柱齿轮精度.中华人民共和国国家质量监督检验检疫总局发布.2001-12-17发布.2002-06-01实施.
[31]庄葆华,李真。齿轮近代测量技术与仪器.机械工业出版社.1984年.
[32]胡文金.计算机测控应用技术.重庆大学出版社.2003年.p23
[33]费业泰.误差理论与数据处理.机械工业出版社.2000年.
[34]柏永心.渐开线圆柱齿轮精度.陕西科学技术.1988年.
[35]孙传友,孙晓斌等。测控系统原理与设计.北京航空航天大学出版社,2002年.
[36]孙传友。测控系统原理与设计.北京航空航天大学出版社.2002年.
[37]高金源。计算机控制系统.北京航空航天大学出版社.2001年.
[38]甘永立。几何量公差与检测(第四版).上海科学技术出版社.
[39]沙定国。误差分析与测量不确定度评定.中国计量出版社.2000.
[40]吴玉梅,张琳,朱利强,郭俊杰等。基于电子展成与坐标结合原理自动测量圆柱齿轮的研究.宇航计测技术,22(4),2002:17-21
[41]杨瑛。齿向误差的测量方法及误差分析.计量与测试技术,6,2001:10-14
[42]Ax4810GPIB interface card user's manual.TaiWan:AXIOMTEK Co.,Ltd.Mar,2004.
[43]OPERATOR'S MANUAL 3000-4 GRSR ANALYZER.USA:M&M co.,Ltd.
[44]ELECTRICAL SYSTEM MANUAL FOR 3000-4 GRSR ANALYZER.USA:M&M co.,Ltd.
[45]孙桓,陈作模。机械原理.高等教育出版社,1995.
[46]石照耀,费业泰,谢华锟.齿轮测量技术100年——回顾与展望.中国工程科学[J].2003(5卷9期):13-17
[47]庄葆华,李真.《齿轮近代测量技术与仪器》[M],1986,机械工业出版社
[48]王安.CNC齿轮测量中心总体设计和软件设计.计量技术[J].2004(5):36-38
[49]吴玉梅,张琳,朱利强等.基于电子展成与坐标结合原理自动测量圆柱齿轮的研究.宇航计测技术[J].2002(8):17-21
[50]劳奇成,尚雅层,王建华等.CNC齿轮测量中心的测控系统.西安工业学院学报[J].1996(9):213-215
[51]王建华,劳奇成,刘波等.CNC齿轮测量中心的原理、特点及关键技术.工具技术[J].1996(30):41-43
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[53]赵怀林.微机测量与数据误差处理方法.电测与仪表[J].2002(5):33-36
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[2]徐建华.图像处理与分析.上海:科学出版社,1992.
[3]张民安.圆柱齿轮精度.北京:中国标准出版社,2002.
[4]王忠,周汝忠.渐开线的圆弧最佳拟合.机械.2003 vol.30增刊.116-120
[5]王俊英,解文涛等.渐开线齿廓单点拟合法及其精度分析.机械加工,2000
[6]赵仲琪,龚振善.渐开线齿廓两点拟合法及其精度分析.制造技术及机床.2000
[7]朱景梓,张展等.渐开线外啮合圆柱齿轮传动.国防工业出版社.1990
[8]刘欣,张元良.微型齿轮量仪及测量技术的研究.工具技术.1993.35-37
[9]李庆杨,王能超等.数值分析.华中科技大学出版社.2001
[10]陈向伟,王龙山,图像测量技术在微型齿轮测量仲的应用.半导体光电.2004.No.6.465-469
[11]夏正良.数字图像处理.东南大学出版社.1999.1
[12]WeijingLi,Carbollo.M.High-speed micro gear inspection by evaluating Laser beam reflectiongs.Intelligent Engineering Systems Through Artificial Neural Networks.Vol.41994.987-992
[13]张国雄.三坐标测量机[M].天津:天津大学出版社,1999:1-6,138-174.
[14]王志,谢华锟,王贵成.锥齿轮测量原理以及测量仪器最新进展[J].电测与仪表.2005,42:37-39.
[15]李瑛,肖耘亚.齿轮测量及反调技术在螺旋锥齿轮生产中的应用[J].现代制造工程.2004,4:71-72.
[16]魏华亮.我国CNC齿轮测量中心的发展现状[J].计量技术.2004,10:33-34.
[17]于晓伟.螺旋锥齿轮铣齿机结构发展的研究[J].机械研究与应用.2006,19:95-96.
[18]郑江,张保全,桂志国.现代齿轮技术的发展与我国齿轮制造面临的问题[J].华北工学院学报.1997,18(1):50-54.
[19]卢贤缵,尚俊开.圆弧齿轮啮合原理[M].北京:机械工业出版社,2003:36-71.
[20]李特文.齿轮啮合原理[M].第二版.上海:上海科学技术出版社,1984:412-425.
[21]李特文.齿轮啮合原理[M].第一版.上海:上海科学技术出版社,1964:240-322.
[22]第一汽车厂切削实验室编.圆弧齿伞齿轮加工手册[M].第一版.长春:吉林人民出版社,1959:1-10.
[23]齿轮手册编委会.齿轮手册(上册)[M].第二版.北京:机械工业出版社,2002,5:3-75.
[24]齿轮手册编委会.齿轮手册(下册)[M].第二版.北京:机械工业出版社,2002,20:3-83.
[25]昌明.齿轮测量中心测控系统开发[D].西安:西安理工大学,2006:5-10.
[26]陈海燕,陈祥熙,路淳豪.三维坐标中测量曲面的定位[J].光学仪器.2000,22(6):3-7.
[27]王沫然.MATLAB与科学计算[M].北京:电子工业出版社,2003:257-264.
[28]苏金明,张莲花,刘波等.MATLAB工具箱应用[M].北京:电子工业出版社,2004:258-262.
[29]陈立周.机械优化设计方法[M].第三版.北京:冶金工业出版社,2005:89-105.
[30]渐开线圆柱齿轮精度.中华人民共和国国家质量监督检验检疫总局发布.2001-12-17发布.2002-06-01实施.
[31]庄葆华,李真。齿轮近代测量技术与仪器.机械工业出版社.1984年.
[32]胡文金.计算机测控应用技术.重庆大学出版社.2003年.p23
[33]费业泰.误差理论与数据处理.机械工业出版社.2000年.
[34]柏永心.渐开线圆柱齿轮精度.陕西科学技术.1988年.
[35]孙传友,孙晓斌等。测控系统原理与设计.北京航空航天大学出版社,2002年.
[36]孙传友。测控系统原理与设计.北京航空航天大学出版社.2002年.
[37]高金源。计算机控制系统.北京航空航天大学出版社.2001年.
[38]甘永立。几何量公差与检测(第四版).上海科学技术出版社.
[39]沙定国。误差分析与测量不确定度评定.中国计量出版社.2000.
[40]吴玉梅,张琳,朱利强,郭俊杰等。基于电子展成与坐标结合原理自动测量圆柱齿轮的研究.宇航计测技术,22(4),2002:17-21
[41]杨瑛。齿向误差的测量方法及误差分析.计量与测试技术,6,2001:10-14
[42]Ax4810GPIB interface card user's manual.TaiWan:AXIOMTEK Co.,Ltd.Mar,2004.
[43]OPERATOR'S MANUAL 3000-4 GRSR ANALYZER.USA:M&M co.,Ltd.
[44]ELECTRICAL SYSTEM MANUAL FOR 3000-4 GRSR ANALYZER.USA:M&M co.,Ltd.
[45]孙桓,陈作模。机械原理.高等教育出版社,1995.
[46]石照耀,费业泰,谢华锟.齿轮测量技术100年——回顾与展望.中国工程科学[J].2003(5卷9期):13-17
[47]庄葆华,李真.《齿轮近代测量技术与仪器》[M],1986,机械工业出版社
[48]王安.CNC齿轮测量中心总体设计和软件设计.计量技术[J].2004(5):36-38
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